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Breakdown
YP Chawla
Hd. Energy Sector
Apollo Tyres
ypchawla@gmail.com
+91 98107 08707
How much Time it takes to Replace a Car
Tyre ?
Replacing 4 Tyres ?
the sub-three
sub three second range to change a set of tyres!
The last time F1 had refuelling- recorded
tyre change in F1 – 3.2 seconds. -1993
Asset
Doctor
Drivers of the Today
Today’ss Economy
• higher returns
returns, higher growth , higher
productivity, with increased wage bills, fast
changing technologies , Capacity
Additions, slow down in economy
Zero breakdowns at our plants
Is it conceivable-or even desirable-to have zero
breakdowns?
Is it not a Political Statement only?
Zero Wastage
Zero Defect
Z
Zero Breakdown
B kd
Fosbury
Basically
y a Gymnast
y - Not successful
Applied principles of Gymnastics to High Jump
Result - A Quantum Jump
X Vibration d located
X Oil
erforman
X
Noise
1 X
Preventive maintenance time-
Heat
Pe
and usage-
usage
X
based strategies
Time
Design for Maintainability
Prepare operational specifications and
Evaluate procedures,, develop
p p maintenance and Maintainability checks RCM
development options inspection strategies, prepare input to asset
reference plan, develop facility data
M
Mapping
i ttotal
t l costt – the
th practical
ti l side
id Total cost
Time/Usage
Asset Management
Plans
Strategic
Initiatives
Annual Budgets
Renovate
• Concluding Remarks: Successful Zero Breakdown
Maintenance is built on the following Hall mark
fundamentals:
• Zero breakdown equipment needs quality design, low-
stress and less fatigued parts kept in good health.
• Zero breakdown maintenance - to stop human error from
causing
i plant
l t andd equipment
i t ffailures
il needs
d a tteam off
Talented Top Persons geting involved right from Indenting,
Procurement, Selection & Design Stage, Know the
Financials returns on Asset Capital Cost and can
Financials,
undertake work in pressure conditions with a good team
work with appropriate updating in knowledge for the Vital
Equipment, processes, Processes, economics of
outsourcing Maintenance, IT’s role, Removing operational
risks of the Asset & Plant for benchmarking the
Performance with integrated operational risk management
across the
th equipment
i t life
lif cycle
l , and d th
the B
Bestt P
Practices
ti iin
Maintenance and Reliability.
• A Parting suggestion Organizations need to redefine
what businesses they're in and want to be in, re-
evaluate processes, rationalize systems, benchmark
and measure, and create new sources of revenue out
of its Operations of World-Class Maintenance
Management Success.